Translamatic Robotic Welder is a computer controlled arc-welder that utilizes a coated wire without gas.This technology is very useful in reconditioning of CMS X-ing in Railway.

2.  A turnout is one of the weakest links in the permanent
way system and requires continuous attention and
maintenance for ensuring their proper geometry, service
performance and above all safety.
 In certain high traffic density areas the points &
crossings wear out within a very short period. Wear
usually involves progressive loss of material due to
relative motion between the two contacting surfaces
(i. e. rail and wheels).

3.  The cost of these components is comparatively much higher
than any other P. Way material. Therefore to enhance the
service life of these components reconditioning of worn-out
area by a combination of metal arc welding technique and
consumables have been introduced.
 Translamatic Robotic Welder is a computer controlled arc-
welder that utilizes a coated wire without gas.
 Initially it is done in Northern Railway and then introduced in
other Railways. After successful trial Railway Board vide letter -
Track/21/2007/0401/7/CMS XING Dated 17.02.2010 and
further by letter dated 17.10.2010 approved the reconditioning
of worn out CMS Crossing by Translamatic Robotic Welding.

4.  Eliminates operator exposure to weld fumes.
 Records all welding events into memory for later
download to PC.
 Memory adapter, PC adapter, and software available as
an option.
 Automated control provides consistent welds.
 Weld bead, patterns, and dimensions all electronically
controlled.
 Automatic call-up from memory.
 Rugged lightweight construction.

5. Translamatic Robotic Welding

6.  Before taking up In-Situ Reconditioning of CMS X-ing,
removal of hardened metal , spelled edges, surface cracks
and micro cracks are necessary. It is desirable to reach up to
parent & sound layer.
 The surface preparation is done by hydraulic grinders.
The care shall be taken that no localized grinding shall be
done to avoid the excess heat generation.
 Dye-penetration test after grinding is to be done in order
to ensure surface to be reclaimed free from cracks.

12.  It is done by a ‘Translamatic Robotic welding’
machine. This is a very handy machine. It can be lifted
by merely two persons. It works through software, data
for which shall be feed in the data logger.

14.  Data of area to be covered under welding is to be fed in a
device called ‘Charlie’ Maper by Horizontal polygon
and/or triangles on all three areas one by one.

15.  Welding is done automatically without any manual
interference, eliminating manual errors.
 Welding each layers start & stop controlled by Charlie
Maper.
 Temperature should not be more than 100 degree at the
start of each bead. No more than one run shall be
deposited. The TRW is programmed in such a manner to
follow skip welding sequence or to weld different portion
of the X-ing by rotation.
 The first round of Welding shall be done for wing rails
(right and left) and nose of crossing.

17.  After completion of first round of welding slag shall be
removed by wire brush and light hammer.

18.  Welding of the wing rail and nose of crossing for the
remaining portion shall be completed gradually.

19. In order to obtain smooth finish profile and surface of
welded CMS crossing grinding by DISC Grinding
shall be done.

23.  As per “Manual for
reconditioning of MM
Steel, point &Crossing,
SEJ and CMS
Crossing”.

24.  The reconditioned crossing after finish grinding shall
be subjected to visual inspection, dimensional
measurement and freedom from presence of any
surface defects during welding i.e. undercut, slag,
porosity, cracks etc.
 If it is found free from any defects during visual
inspection then dye penetration test to be carried
out to check any defects which are not found in visual
inspection.

26.  A speed restriction of 30kmph with OES+BLW is
required during the work. Other necessary track
protection arrangements have to be followed.

27.  Operators/Applicators should be duly certified by the
original technology providers of RDSO approved.
 The work should be confirm to “Manual for
Reconditioning of Medium Manganese (MM) Steel
Points & Crossing Switch expansion joints (SEJ’s) and
Cast Manganese Steel (CMS) Crossings-1996”
published by RDSO, Lucknow.

28. Sl.N
o.
Description
of Items
Conventional
Reconditioning
Translamatic
Robotic
Reconditioning
1. Type of Welding Metal Arc Welding Core flux continuous feeding
2. Method of Welding Manual by Metal arc
welding
Automatic by Robotic in situ
welding method
3. Time Required for
Welding
More Less
4. Manpower
required
More (Up to 8 labours)
However additional 10
labours require for removal
and insertion of crossing
each time
Less ( Up to 6 labours )
5. Heat Input More Approximately 50 % less heat
input
than Metal arc welding is
required.

29. 6. Metal Deposit over
Rail
Head after welding
Up to 3 mm up to 0.5 mm
7. Temperature
control
1. By water cooling 2.
Cooled air spray 3. Cooled
water spray
By giving less Heat input
8. Durability Depends on type of Welding
Electrodes used. 1. up to 15
GMT if H3 electrode used.
2. Up to 25 GMT if H3A
electrode is used.
3. up to 35 GMT if H3 B
electrode used. And
Maximum is 35 GMT
Minimum up to 80 GMT
9. Essentials Additional spare CMS Xing
is required
Not required as welding is
done in
situ
10. Disturbance to
adjoining track
Approach rail / gapless joint
disturbed during removal
and insertion of CMS Xing
No disturbance to adjacent
track

30. Thank You